Thermally insulated wall structure



July 14, 1936. J. H. THOMAS THERMALLY INSULATED WALL STRUCTURE Filed April 25, 1954 2 Sheets-Sheet l I [III II I I IIIIIIIIIIIIIIII IIIIIIIIIIIIIIIIIIII If H JE IY July 14, 1936.

J. H. THOMAS THERMALLY INSULATED WALL STRUCTURE Filed April 23, 1954 2 Sheets-Sheet 2 Patented July l4, 1936 UNITED STATES PATENT OFFICE 2,041,236 THERMALLY- INSULATED WALL s'rn'oc'runn John H. Thomas, New York, N. ,Y., asslgnor to Richard Laurence Parish, New York, N. Y.

Application April 23, 1934, Serial No. 721,869

11 Claims.

My invention relates to wall structure and it has to do more particularly with thermally insulated walls.

One of the objects of my invention is to provide improved wall structure o!v the foregoing character which is of simple construction, is easy to construct and install, and is highly efficient in its ability to insulate against the transfer of heat by radiation, convection and conduction.

Another object is to provide improved means for insulating walls and particularly walls which include a wall-finishing surface such as plaster or v the like.

- Still another object is to provide means for thermally insulating a wall which eliminates the usual lathing and. which is adapted to receive and support plaster or other wall-finishing materials. Anadditional object is to provide an improved all-metal thermal insulation for walls which in-,

cludes a plurality of spaced metallic sheets formed of a material of sufficient stiffness and thickness to withstand preformed shape and which possesses relatively low reflective characteristics when exposed to visible radiation and relative y high reflective characteristics when exposed to structure; and to provide a wall structure where- 7 in the transfer of air therethrough by infiltration 40 is reduced to the minimum.

. Other objects and advantages will appear as --this description progresses and by reference tothe drawings wherein,--- Figure 1 is an elevational plan view 0! one tom 45 of wall structure embodying my invention, certain of the parts being cut away to more clearly illustrate the relationship oi the parts;

Fig. 2 is a section 2-2 of Fig. 1; 50 Fig. 3 is a section taken substantially on line 3-3 of Fig. 2; and

\Fig. 4 is a fragmentary view similar to Fig. 3 sh wing another form of my invention.

e wall structure illustrated in the drawings 55 is of a character which may be employed in vaplastic condition. The projections l8 are or such ken substantially on 'n-ne ter that, when the plaster finally sets and hardens, it is firmly supported by the metallic sheet 50 rious forms of building structures. It is to be understood, however, that the invention is not limited to this particular form of structure, but it has utility in various other structures wherein similar conditions of use are to be met. Also, while the drawings show my invention applied to an outer wall structure, it may be equally well applied to inner walls including ceilings and floors of buildings and other enclosures.

The wall structure shown inthe drawings in- 10 cludes vertical stud members i0 and horizontal cap and sillmembers II and I2 which define the edges of a plurality of wall spaces l3 along each wall. The outer part of each space I3 is covered by the usual boxing l4 and an outer finishing surface i5 which may take the form of weatherboarding or any other suitable structure. The inner side of each space I3 is covered by a wall unit "-2! with which this invention is concerned. This unit includes a metallic sheet i6 20 which supports a wall-finishing covering II which, preferably, takes the form of plaster. It is to be understood that, although various forms of plaster are well suited as the finishing covering, other forms of material which may be secured to the 25 sheet l6 may be used in certain instances without departing from my invention.

The plaster covering I1 is secured to the metallic sheet 18 in the following manner: a plurality of projections it are struck outwardly from and 'at an angle with respect to the outer face of the sheet l1, thereby providing openings I! in such sheet inwardly of and directly behind the projections l8, which are disposed fairly close together. The projections it are arranged in horizontal rows and theprojections in adjacent rows are staggered with respect to each other (Fig. 1) The plaster" is applied to the sheet in the usual size and so spaced apart that, when they are im- 40 bedded in the plaster, the plaster covering, even in its original plastic state, is supported in its intended position. A small portion of the plastic plaster flows through the openings l9, as indicated at 20, thereby providing an additional interlocking bond between the sheet I6 and the plaster covering I 1. This bond is of such a characagainst both vertical and outward displacement. It will be seen from the foregoing that the metallic sheet It eliminates the use of the lathing heretofore employed; and this sheet, while supporting the plaster, also serves to reduce to the minimum the transfer of air through the plaster by infiltration.

The metallic sheet It also plays a part in insulating against the transfer of heat through the wall space |3 by radiation, convection, and conduction. To that end, the sheet "5 is formed of a metallic material which possesses relatively low reflective characteristics when exposed to radiation of wave lengths within the visible portion of the electromagnetic spectrum and relatively high characteristics when exposed to radiation of longer wave lengths than the visible portion of the electromagnetic spectrum, or a material of the character disclosed in Letters Patent No. 1,910,703, granted to Joseph M. LeGrand, on May 23, 1933. Such a material possesses relatively low reflective efliciency when exposed to visible radiation and relatively high reflective efficiency when exposed to infra-red radiation as is the case in the use of structure embodying my invention. Commercial black steel well serves this purpose and I, therefore, preferably, form the sheet Hi from such material, which is of sufficient stiffness and thickness to withstand preformed shape and to readily support the plaster covering H.

In providing against the transfer of heat through the space |3 by radiation, convection, and conduction, I mount another metallic sheet 2| in the space I3. The sheet 2| is mounted closer to the metallic sheet l6 than to the outer wall unit |4|5 so as to divide the space l3 into a plurality of variable-depth spaces l3 and I3 the shallower of which is the space l3 between the sheets I6 and 2|.

The metallic sheet 2| is, preferably, formed of the same material as the sheet l6 and it is also of suificient thickness and stiffness to retain preformed shape. Its surface is preformed to provide therein a plurality of angular and intersecting plane surfaces 22 which afford increased insulation effect. Ribs 23 are provided at the intersections of the plane surfaces 22 to add strength and rigidity to the sheet 2| and to prevent detrimental vibration thereof.

The metallic sheet 2| is supported by the vertical stud members It! in substantially parallel relaof the stud members It beneath the side edges of the sheet Hi. The offset portions 25 of the flanges 24 determine the spacing of the sheets l6 and 2| 'and this offsetting may be varied to suit variable width wall spaces and various conditions of use, all without departing from my invention. For instance it will be noted that the spacing nearest the inside of the wall is less than that nearest the walls outside surface. This is in accordance with the teachings in the above-mentioned Le Grand patent, where it is shown that greater insulation efliciency results when the narrower space is nearest the hot side of the walland in this instance, since the temperature variations are greater in winter and the wall is designed primarily for the saving of fuel at that season, the hot side is considered to be the inside of the wall.

In the installation of the structure so far described, the inner sheet 2| may be first inserted in place, after which the sheet I6 is applied, and both of these sheets are simultaneously secured to the stud members In by fastening devices 26 passing through the side edges of both sheets at spaced points therealong. Both of these metallic sheets, preferably, extend throughout the height of the space I3 and the inner sheet 2| is of such length that its opposite ends snugly abut the cap 5 and sill members I and I2 (Fig. 2). In this way the substantially parallel air spaces l3 and Ill are substantially sealed apart from each other.

The spaces l3 are usually of comparatively narrow width" and,in certain cases, I may employ l0 wall-formingmetallic sheets |6 of suflicient width to cover two or more of these spaces. An arrangement of that character is shown in Fig. 4. In that case, the inner wall-forming sheet 21 which supports the plaster 28 is of suflicient width to span 15 two successive spaces 29. If desired, a single sheet like sheets 2| may be employed for each space 29 or a single sheet 30 may be used for two (or more) successive spaces 29. In either case, the sheets 21 and 30 are, preferably, formed of 20 the same material, and correspond in other respects, to the sheets l6 and 2|; except, however, where a single sheet 30 is employed for two spaces, such sheet is provided with a vertically-extending offset portion 3| providing a pocket 32 of 25 such size and shape as to snugly receive the side edge portion of the upright stud member 33. If a single sheet 30 extends into more than two spaces 29, the desired number of pockets 32 are provided to accommodate additional stud mem- 30 bers 33. In this form, the sheets are applied and secured by fastening devices 34, after which the plaster 28 is applied and permitted to harden and set to complete the finished wall'surface.

It is believed that the operation and advan- 35 tages of my invention will be fully understood from the foregoing. By employing metallic sheets formed of the material hereinabove specified and arranged as described the transfer of heat by radiation, convection, and conduction is practically reduced to the minimum. Furthermore, my invention provides a simple and inexpensive insulation means which eliminates the use of the usual lathing and which, in turn, serves to directly support the plaster or other wall-finishing ma- 45 terial. This arrangement gives to the user, at the minimum of cost, a substantially permanent wall structure which aifords high insulation efficiency for practically the life of the structure insulated. My invention also, through its insulation ability and by minimizing air infiltration, reduces the cost of heating homes, buildings and other enclosures, as well as aiding in the maintenance of more nearly uniform temperature condition. Wall units embodying my invention may be readily shipped,'stored and installed.

It will be understood that while I have shown and scope of claims which follow. For example, without limiting the foregoing generality, a greater number of metallic sheets may be mounted in the wall 65 spaces in spaced relation with respect to each other and the inner and outer walls which sheets may be provided with edge flanges that may be readily secured to the upright stud members. Also, the projections I8 instead of being struck out from the metallic sheets l6 and 21 may, if desired, be separate members secured to the sheet by welding or otherwise.

I claim:

1. In structure of the class described, an outer 75 wall, support members therefor, an inner wall secured to said support memberssaid inner wall comprising a sheet of ordinary metal having members projecting from one face thereof, a wall finishing covering carried by said sheet and interlocked with said projected members, and another metallic sheet of steel having a high heat-reflectivity surface and mounted in the space between said two walls in spaced and substantially parallel relation with respect thereto. said metallic sheets being spaced substantially closer together than said outer wall and secondnamed metallic sheet.

2.. In structure of the class described, an outer wall, support members therefor, an inner wall secured to said support members, said walls and support member'sforming a plurality of separate spaces in substantially the same plane, said inner wall comprising a sheet metal section having members projecting from one face thereof, a wall finishing covering carried by said section and interlocked with said projected members, and a metallic sheet mounted in each of the spaces between said two walls'in spaced and substantially parallel relation with respect to said walls, both said metallic section and said metallic sheet being formed of a steel material having high heat-reflectivity and having contacting portions of their surfaces fastened at common points to said support members.

3. In structure of the class described, an outer wall, support members therefor, an inner wall secured to said support members, said inner wall comprising a sheet of shape-retaining commercial black steel having members projecting from one ering carried by said sheet and interlocked with said projected members, and another commercial black steel sheet having a surface of'high heatreflectivity and mounted in the space between said two walls in spaced and'substantially parallel relation with respect thereto.

4. In structure of the class described, means forming wall spaces to be insulated and including a series of vertical and spaced supporting members, an outer wall member carried by said supporting members, and an inner wall carried by said supporting members, said inner wall comprising a sheet member, a wall-finishing covering for said sheet member, means between said sheet member and said covering for bonding the same together as a unit, and another sheet member mounted in each of said spaces and secured to said supporting members in spaced and substantially parallel relation with respect to said first sheet member and said outer wall and constructed and arranged to divide each of said spaces into a. plurality of air chambers substantially sealed apart from each other, both of said sheet members being formedof a comparatively thin steel material of suiiicient thickness and stifiness to retain preformed shape and which has higher reflective characteristics-when exposed to infra-red radiation than when exposed to visible radiation.

5. In structure 'of the class described, an outer wall, support members therefor, an inner wall secured to said support members, said inner wall comprising a metallic sheet, a wall-finishing covering, said metallic sheet being provided with uni-directional means for securing said covering thereto, another metallic sheet mounted in said space between said two walls in spaced and substantially parallel relation with respect thereto, said latter metallic sheet being also fixedly seface thereof, a wall finishing ,cov-' cured to said support members along the edges of the former whereby said space is subdivided into a plurality of air spaces substantially sealed apart from each other.

6. In structure of the class described, an outer wall, support members therefor, an inner wall secured to said support members and defining a substantially rectangular space of comparatively shallow depth, said inner wall comprising a metallic sheet, a wall-finishing covering thereon, means for securing said covering to said metallic sheet, and another metallic sheet mounted in said space between said two walls in spaced and substantially parallel relation with respect there-v to, said second metallic sheet having a body portion of substantially the length and width of said space and laterally-flange parallel-surface means around the edges thereof adapted to be fixedly secured to said support members to subdivide such space into a plurality of substantially parallel air spaces substantially sealed apart from each other, both said metallic sheets being fastened to the support members by common fastening means.

7. In structure of the class described, means forming a wall space, said means including a wall unit comprising a metallic sheet having a pinrality of projections struck therefrom and providing a like number of openings therein, and a'wallfinishing covering mounted upon said metallic sheet on its side having said projections, said covering being of a character adapted to be applied in a plastic condition and to finally set and harden to provide a finished surface, said covering in its plastically-applied condition being adapted to embeddedly receive said projections and to flow through said openings to fixedly bond said-covering to said metallic sheet, and all said projections being so formed that they project upwardly from the bottoms of said openings to facilitate passage of said plastic covering through said openings.

8. In structure of the class described, means forming a wall space, said means including support members and a wall unit secured thereto and comprising a metallic sheet having a plurality of projections struck alike number of openings therein from the bottoms of which said projections extend'upwardly,

and a wall-finishing covering mounted upon said metallic sheet on its side having said projections,

said covering being of a character adapted to be applied in a plastic condition and tofinally set and harden to provide a finished surface, said covering in its plastically-applied condition being adapted to embeddedly receive said projections and to flow through said openings to fixedly bond said covering to said metallic sheet, and another and imperforate metallic sheet mounted in said space in spaced and substantially parallel relation with respect to said first metallic sheet, both of said metallic sheets being formed of a material of sunicient thickness and stiffness to.

retain preformed shape and possessing higher reflective characteristics when exposed to infrared radiation than when exposed to visible radiation, and means for fixedly securing both said sheets to said support members.

9. In structure ,of the.class described, successive support members and wall means forming a plurality of spaces all in substantially the same plane, said'means to cover a plurality of said spaces, a wall-finishtherefrom providing including a wall unit comprising a steel sheet of high heat-reflectivity adapted ing. covering. means by which said covering is securely bonded to the outermost face of said metallic sheet, and another single metallic sheet of substantially the same material and outline dimensions of said first sheet spanning the spaces covered by said first sheet inspaced relation to the latter and sub-dividing each of the spaces covered by said first sheet into a plurality of separated air spaces, and common means fixedly securing both of said sheets to said support members.

10. In structure of the class described, an outer wall, upright supports therefor, a steel shape-retaining sheet of high heat-reflectivity secured to said supports and serving as an inner spaced wall member, said supports dividing the space between said walls into a plurality of successive spaces all in substantially the same plane, another metallic sheet secured to said supports within said space in spaced relat1on to said inner wall metallic sheet, said second sheet extending laterally past one or more of said supports into and spanning a plurality of said successive wall spaces to divide each of the latter into a plurality of air spaces, and means for fixedly securing said metallic sheets to said supports.

11. In structure of the class described, an outer wall, an inner wall mounted in spaced relation to said outer wall, said inner wall comprising a metallic sheet of suflicient stiffness and thickness to withstand preformed shape and having a plurality of rows of projections extending from one face thereof, said projections being arranged in rows with the projections in adjacent rows staggered with respect to each other, a wall finishing covering upon said sheet and interlocked with said projections, and another and imperforate metallic sheet mounted between and in spaced parallel relation with respect to said inner and outer walls, said latter metallic sheet being of a character possessing relatively higher reflective characteristics when exposed to infra-red radiation than when exposed to visible radiation.

JOHN H. THOMAS. 

